Rug making device and method of use

ABSTRACT

The present invention relates to an improved rug, and to the means for making such a rug. The disclosed rug making device has a configuration that comprises a window; and winding a rug yarn helically around the device causes the individual turns of the rug yarn to span the window in a transverse direction. The central portion of the individual turns of the rug yarn are then sewn to a rug base; and the individual turns are then cut at a cutting guide of the device. The result is plurality of strands of rug yarn that have their mid-points affixed to the rug base; and have the free ends fluffed out from the rug base, to form the finished rug.

[ Oct. 23, 1973 RUG MAKING DEVICE AND METHOD OF USE [76] Inventor: Myrtle B. Mc Hale, 10662 Amber Cir., Garden Grove, Calif.

22 Filed: May 7,1971

21 Appl.No.: 141,223

2,450,695 10/1948 Siefert et al. 112/9 X 2,507,907 5/1950 Kanehllm, 112/9 2,581,703 1/1952 Reilly, 112/9 FOREIGN PATENTS OR APPLICATIONS 596,450 1/1948 Great Britain 112/9 663,512 12/1951 Great Britain 112/9 Primary Examiner-Alfred R. Guest Att0rneyNienow & Frater [57] ABSTRACT The present invention relates to an improved rug, and to the means for making such a rug. The disclosed rug making device has a configuration that comprises a window; and winding a rug yarn helically around the device causes the individual turns of the rug yarn to span the window in a transverse direction. The central portion of theindividual turns of the rug yarn are then sewn to a rug base; and the individual turns are then cut at a cutting guide of the device. The result is plurality of strands of rug yarn that have their mid-points affixed to the rug base; and have the free ends fluffed out from the rug base, to form the finished rug.

11 Claims, 3 Drawing Figures PATENIEUMI 23 .m

FIG.

FIG.3

. 1 RUG MAKING DEVICE AND METHOD OF USE BACKGROUND attention being directed particularly to NEW IDEAS IN RUG YARN and to FLUFF RUGS, both issued by the Lily Mills Company of Shelby, North Carolina.

The prior art method of making a fluff rug is to use a rug base or rug foundation of material such as burlap; this having a plurality of marking dots that may be spaced as closely as one quarter of an inch apart. A length of rug yarn.is then formed into individual bundles, each bundle containing about 17 strands of rug yarn about two or three inches'long; the size of the bundle depending upon the desired effect, the marking dot spacing, the diameter of the rug yarn, etc. The bundle is then formed to a tuft or tassel, by stitching a short length of suitably colored thread or rug yarn to the rug base adjacent one of the marking dots; leaving a loop into which the above mentioned bundle is inserted about half way. The loop is then tightened, and knotted; this holding the bundle firmly in place, and forming a tuft. A plurality of such tufts are positioned in accordance with the marking dots; and the tufts are then.fluffed out" to form the finished rug.

For a more decorative effect, the pattern of marking dots is suitably coded by size, color, darkness, etc.; each of these code indications representing a different color tuft to be used at that marking dot location. The end result is thus an extremely decorative and useful rug or covering.

As may be realized from the above discussion, the preparation and sewing of many such individualtufts becomes a onerous task. Moreover, when the tufting is performed by a novice, there is a tendency for the tufts to be irregularly spaced and of irregular height. Therefore, many people Shy away from making fluff rugs.

' OBJECTS AND DRAWINGS It is therefore the principal object of the present invention to provide an approved fluff rug.

It is another object of my present invention to provide an improved fluff rug wherein the tufts are automatically more regular in location and in appearance.

It is still another object of my present invention to provide an improved fluff rug that is easier to make.

It is a further object of my present invention to provide an improved device for making fluff rugs.

It is a still further object of my present invention to provide an approved rug making device that permits even novices to make quality fluff rugs the first time.

The attainment of these objects and others will be realized from a study of the following detailed description, taken in conjunction with the drawings, of which FIG. 1 shows a single individual tuft of a prior art fluff FIG. 2 shows a simplified device for producing animproved fluff rug; and

FIG. 3 shows an improved rug making device for producing an improved fluff rug.

SYNOPSIS Broadly speaking, the present application discloses a rug making device that has a working window with sidewalls having straight central portions and outwardly bowed ends; so that individual turns of a rug yarn do not slip off the device. A pair of longitudinal spaced apart retaining strands, preferably helically coiled wires, retain the individual turns of rug yarn, so that their center portions may be: sewn to a rug base. The individual turns of rug yarn are then cut at a cutting guide of the device; providing a rug with equally spaced and equal length strands of rug yarn.

PRIOR ART TUFTING The basic construction of a fluff rug will be understood from FIG. 1, which illustrates a rug base 10 having a plurality of marking dots 11.. As discussed above, some of these marking dots 11 may be coded to indicate that a different color of rug yarn is to be used at those locations. A bundle 12, comprising a plurality of individual strands 13 of yarn, is held to rug base 10 by a loop 14 of rug yarn or thread that is sewn to the rug base 10, suitably knotting or stitching of the loop 14 being used to hold bundle 12 in place.

It will be realized, as discussed above, that irregular placement of the tuft 12 and/or irregular length of strands 13, may produce an undesirable appearance. Of course, when made by an expert, smaller, more numerous, and closer spaced tufts will improve the overall appearance of the fluff rug; but this rug construction requires more detailed sewing, knotting, placement, etc.

DESCRIPTION THE BASIC RUG MAKING DEVICE FIG. 2 illustrates a simplified rug making device for producing an improved fluff rug, even when used by a novice. Basically, the rug making device 16a resembles a two pronged fork; and has a handle portion 17a and two substantially parallel longitudinally extending sidewalls 18a; the sidewalls 18a and the interior wall 19a of handle portion 17a forming a working window 20 between them. Each sidewall 18a has a cutting guide 21a, indicated in FIG. 2 to be a horizontal longitudinally extending slot on the outer surface of the side- I walls.

In preparation for use, a length of given color rug yarn 22 is helically wound around the spaced apart sidewalls 18a, whose outer surface may, if desired, be

lation, without any turn of the rug yarn overlapping any other turn of the rug yarn. The free: ends of the rug yarn 22 may be held from unwinding by any suitable means, such as, for example, taking a few .turns around the slot portion of the sidewall.- t

The thus prepared wound rug making device 16a is now placed on top of the rug base 10, stradling a row of marking dots 11 coded to receive the same color rug yarn. The sewing foot 25 of an ordinary sewing machine is then passed over the center portion of the individual turns 23 of rug yarn; so that the sewing needle 26 leaves a row of stitches 27 that fasten the central portion of each turn 23 of rug yarn to the rug base 10. If desired, a narrow strip of basting material may be used to assure better holding of the rug yarn turns 23 to the rug base 10.

When the sewing operation has been completed, a cutting device 28, such as scissors, a knife, a razor or the like, is inserted into the cutting guide 21a; and severs the upper portion of each turn 23 of rug yarn from the lower portion of adjacent turns 23 of rug yarn. The cut ends 29 of the rug yarn now flare away from the sidewalls 18a; and are ready for fluffing.

The sewing foot 25, which may have been left in position to aid in the holding of the individual turns 23 of rug yarn during the cutting operation is now raised and/or backed off; and the rugging device 160 is now lifted from rug base 10, preparatory for repetition of the above operations.

The rugging device 16a is again wound with rug yarn; and the above described procedure is repeated as often as is required to produce a fluff rug of the desired size. If a multi-color effect is wanted, it is merely necessary to use the specified color of rug yarn at the indicated locations; each color covering as little or as large an area as required.

It will now be realized that the use of the disclosed rugging device 16a will produce a fluff rug in which each strand of rug yarn in individually positioned, uniformly spaced, of uniform length, and sewn firmly in place; this being achievable by anyone with even limited sewing skill, and resulting in an attractive fluff rug.

In order to facilitate the aligning of the rugger device 16a with the pattern of marking dots 11, the device 16a comprises an indexing mark 300 on its handle portion 17a; this indexing mark 30a being positioned adjacent one of the marking dots 11. In this way,.the rugger device l6a maybe readily positioned in such a way that the resultant row of stitches 27 falls more properly onto the row of marking dots 11.

IMPROVED EMBODIMENT It will be realized that as the rug yarn 22 is progressively wound around the rugger device 16a, the later made turns 23 approach the open end of the rugger device window 20; and their tension has a tendency to close up ,the' open end of the window 20 by causing the free ends of the sidewalls 18a to approach each other. This closing up of the window has the effect of slightly shortening the later made turns of the rug yarn relative to the earlier made turns of rug yarn; and when the turns are cut free from each other, the slight differences in length produce a slightly different fluffing'effeet. The overall effect is quite small; but, to the purist, it may produce an undesirable appearance in the finished fluff rug.

An improved embodiment of the rugger device is shown in FIG. 3; this improvement overcoming the above discussed shortcoming, and also providing a facilitated sewing operation. As indicated in FIG. 3, the

improved rugger device 16b comprises a handle portion 17b, and a pair of spaced apart sidewalls 18b; the spaced apart sidewalls 18b and the interior wall 19b of the handle portion forming a window 20 of the type End piece 35 requires that the sewing foot (25 of FIG. 1) be raised and lowered when it is positioned and removed from the rugger 16b; and while this procedure is of no great inconvenience, some operators may want to avoid it. In order to accomplish this facilitated sewing result, end piece 35 may be removably attached to the sidewalls 18b; FIG. 3 indicating that this result may be achieved by forming the end piece/sidewall jointure with ball like configurations 36 that snap removably into suitable socket like receptacles 37. In this way, the end piece 35 may be removeably attached to the sidewalls 18b.

Of course, a completely removable end piece is in danger of being lost or misplaced. To avoid this possibility, one end of the end piece/sidewall jointure may be configured into a captured mode; as by making one of the ball 36/socket 37 combinations pivotable, but non-separatable. This captive arrangement permits the end piece 35 to be pivoted out of the way when the user so desires; and yet causes the endpiece 35 to remain captively attached, so that it cannot be lost or misplaced. Alternatively, the end piece 35 may be permanently affixed to the sidewalls.

It should be also noted that the sidewalls 18b have straight central portions 40, and have outwardly bowed end portions 41; this sidewall configuration permitting the turns 23 of rug yarn to be easily wound onto the straight portions 40, and yet be held from coming off the bowed out end portions 41.

The free ends of the rug yarn 22 may be held from unwinding by tucking them under adjacent turns of the rug yarn; but the improved rugger equipment of FIG.

3, shows the free ends of rug yarn 22 to be held by means small patches of holding material 42, such as pressure sensitive tape, the hook portion of Velcro, etc. Alternatively, rugger 16b may comprise an integrally molded clamp or similar arrangement for holding the free end of rug yarn 22.

The improved rugger 16b of FIG. 3 also comprises an arrangement for facilitating the sewing of the individual turns 23 of rug yarn; it being recalled that the individual turns 23 of rug yarn are positioned transversely of the rugger 16b, and span thewindow 20. Therefore, as

the sewing foot moves across them in a direction that v is longitudinal relative to the rugger 16b, there is a tendency for the individual turns 23 of rug yarn to move slightly under the sewing pressure.

This effect is minimized by the retaining structure 44 of FIG. 3. Retaining structure 44 comprises two parallel spaced apart retaining strands 45 of material that press downward against the turns 23 of rug yarn; and therefore hold the turns against the rug base 10 during the sewing operation.

Strands 45 may comprise a material such as a rubber band or the like; but best results have been obtained by the use of a helically wound spring, this spring having the desirable characteristics that its basically transverse coils hold the individual turns 23 of rug yarn from moving longitudinally under the pressure of the moving sewing foot.

The retaining structure 44 of FIG. 3 is indicated to have one of its ends permanently attached to the bandle portion 17b, and to have its other end removable clipped to the end piece 35, This arrangement has the advantage that the retaining structure 44 may be partially removed during the rug yarn winding operation; and may then be attached for the sewing operation. Al-

ternatively, the retaining device 44 may be completely removable; may have a permanent attachment at the end piece 35; may be positioned at the lower surface of the rugger; etc., depending upon the likes of the particular user and the material used for the retainer.

In order to further facilitate the sewing operation, rugger 16b comprises a first index mark 30b on the handle portion 17b, and comprises a second index mark 300 on the end piece 35; the index marks thus establishing the longitudinal axis of the rugger. By aligning the index marks (and thus the longitudinal axis) with a row of marking dots on the rug base, the wound rugger 16b may be easily and properly positioned relative to the pattern of marking dots. In this way, the resultant row of stitches properly coincides with the row of marking dots. It should be noted that the spaced apart retaining strands 4l5 not only hold down the individual turns of rug yarn for easier sewing; but their spacing provides an improved guide for the movement of the sewing foot between them during the sewing operation.

It should also be noted that the improved rugger 16b of FIG. 3 uses longitudinal cutting guides 21b that are grooves rather than slots; as the grooved structure is appreciably stronger than the previously discussed slots.

It will be recalled that, in use, the rugger is first wound with asuitable number of turns of rug yarn; and is then placed on top of the rug base for the sewing op eration. In order to provide a more positive footing for the rugger, so that it does not move during the sewing operation, its lower surface may comprise a roughened portion, a plurality of protrubances, a series of spikes, or the like.

The disclosed rugger may also be used for forming fringes. For this usage, the rugger 16 is helically wound with rug yarn as discussed above; but the sewing stitches 27 are made as close as possible to the inside edge of a sidewall, say 18a, and only the nearer turns of rug yarn are cut, as in FIG. 2. When the rugger is withdrawn, the turns of rug yarn now take a U- shape, the loose ends forming the fringe.

I claimi.

l. A device for making an improved fluff rug having a rug base and a; plurality of strands of fluffed rug yarn affixed to a surface of said rug base, comprising: i

a handle portion having an interior wall;

a pair of spaced apart sidewalls associated with said handle portion; 1 i said sidewalls and said interio wall defining a working window; means, comprising said sidewalls, for causing a plurality of turns of rug yarn wound around said sidewall portion of said device to span said window; positioning means for retaining the turns in portion along the sidewalls; said positioning means comprising a pair of substantial longitudinally spaced apart positioning elements integral with, and extending outwardly from each of said sidewalls; i

said positioning elements comprising bowed out configurations of said sidewalls located inwardly of the ends of said sidewalls;

a cutting guide extending horizontally and longitudinally along the outside surface of each of said side- 3. The combination of claim 2 wherein said cap type,

enclosing, end piece is removably attached to said sidewalls by a ball/socket configuration.

4. The combination of claim 3 wherein only one end of said end piece is removably attached to one end of one of said sidewalls.

5. The combination of claim 3 wherein said end piece is permanently affixed to said sidewalls.

6. The combination of claim 2 wherein one end of said end piece is removably attached to one of said sidewalls, and the other end of said end piece isswivally attached to the other end of the other of said sidewalls.

7. The combination of claim 5 including retaining structure means, comprising at least one longitudinally extensible strand, for retaining said individual turns of rug yarn during the sewing operation;

said strand being mounted to press downwardly on said individual turns of rug yarn.

8. The combination of claim 7 wherein, said retaining means comprises a pair of spaced apart longitudinally extensible retaining strands that press downwardly on said individual turns of rug yarn.

9. A device for making an improved fluff rug, comprising;

a handle portion having an interior wall;

a pair of spaced apart sidewalls associated with said handle portion;

said sidewalls and said interior wall defining a working window; 1

means, comprising said sidewalls, for causing a plurality of turns of'rug yarn wound around said sidewall portion of said device to span said window;

a cutting guide extending horizontally and longitudinally along the outside surface of each of said sidewalls;

an end piece attached to the free ends of said side-' walls;

said end piece being removably attached to said sidewalls;

one end of said end piece being removably attached to one of said sidewalls;

the other end of said end piece being pivotally nonrernovably attached to the other end of said sidewalls;

retaining structure means for retaining said individual turns of rug yarn during the sewing operation;

said retaining means comprising a pair of spaced apart retaining strands that press downwardly on said individual turns of rug yarn; said retaining strands comprising lengths of helically coiled wire;

. whereby said wound device may be placed on a rug base, the center portion of individual turns of said rug yarn may be sewn to said rug base, said individual turns of rug yarn may then be cut at said cutting guide, and said rug making device may then be removed from said rug base to repeat the above operend piece. ations' from Ill. The combination of claim 10 wherein said side- 10. The combination of claim 9 wherein one end of said retaining strands are permanently affixed to said handled portion of said device, and the other end of 5 bowed end P said retaining strands are removably attached to said wall comprises a straight central portion and outwardly 

1. A device for making an improved fluff rug having a rug base and a plurality of strands of fluffed rug yarn affixed to a surface of said rug base, comprising: a handle portion having an interior wall; a pair of spaced apart sidewalls associated with said handle portion; said sidewalls and said interior wall defining a working window; means, comprising said sidewalls, for causing a plurality of turns of rug yarn wound around said sidewall portion of said device to span said window; positioning means for retaining the turns in portion along the sidewalls; said positioning means comprising a pair of substantial longitudinally spaced apart positioning elements integral with, and extending outwardly from each of said sidewalls; said positioning elements comprising bowed out configurations of said sidewalls located inwardly of the ends of said sidewalls; a cutting guide extending horizontally and longitudinally along the outside surface of each of said sidewalls; means, comprising said handle portion, for placing said wound device on said surface of said rug base; means for sewing the center portion of individual turns of said rug yarn to said surface of said rug base; whereby said individual turns of rug yarn may then be cut at said cutting guide, and said rug making device may then be removed from said surface of said rug base to repeat the above operations.
 2. The combination of claim 1 including means, comprising a cap type end piece attached to and enclosing the free ends of said sidewalls, for spacing apart said ends of said sidewalls.
 3. The combination of claim 2 wherein said cap type, enclosing, end piece is removably attached to said sidewalls by a ball/socket configuration.
 4. The combination of claim 3 wherein only one end of said end piece is removably attached to one end of one of said sidewalls.
 5. The combination of claim 3 wherein said end piece is permanently affixed to said sidewalls.
 6. The combination of claim 2 wherein one end of said end piece is removably attached to one of said sidewalls, and the other end of said end piece is swivally attached to the other end of the other of said sidewalls.
 7. The combination of claim 5 including retaining structure means, comprising at least one longitudinally extensible strand, for retaining said individual turns of rug yarn during the sewing operation; said strand being mounted to press downwardly on said individual turns of rug yarn.
 8. The combination of claim 7 wherein, said retaining means comprises a pair of spaced apart longitudinally extensible retaining strands that press downwardly on said individual turns of rug yarn.
 9. A device for making an improved fluff rug, comprising; a handle portion having an interior wall; a pair of spaced apart sidewalls associated with said handle portion; said sidewalls and said interior wall defining a working window; means, comprising said sidewalls, for causing a plurality of turns of rug yarn wound around said sidewall portioN of said device to span said window; a cutting guide extending horizontally and longitudinally along the outside surface of each of said sidewalls; an end piece attached to the free ends of said sidewalls; said end piece being removably attached to said sidewalls; one end of said end piece being removably attached to one of said sidewalls; the other end of said end piece being pivotally non-removably attached to the other end of said sidewalls; retaining structure means for retaining said individual turns of rug yarn during the sewing operation; said retaining means comprising a pair of spaced apart retaining strands that press downwardly on said individual turns of rug yarn; said retaining strands comprising lengths of helically coiled wire; whereby said wound device may be placed on a rug base, the center portion of individual turns of said rug yarn may be sewn to said rug base, said individual turns of rug yarn may then be cut at said cutting guide, and said rug making device may then be removed from said rug base to repeat the above operations.
 10. The combination of claim 9 wherein one end of said retaining strands are permanently affixed to said handled portion of said device, and the other end of said retaining strands are removably attached to said end piece.
 11. The combination of claim 10 wherein said sidewall comprises a straight central portion and outwardly bowed end portions. 